Waterproof shoe with size and shape-adjustable bootie

ABSTRACT

A footwear system is disclosed for protecting a user&#39;s foot from water or other liquid substances. In one embodiment, the footwear comprises a shoe having an upper, a seamless sock-shaped bootie, an inner lining, and a sole engaged to the upper. The seamless bootie may be composed of waterproof material and include at least one ribbed portion adapted to expand to allow the bootie to conform to the size of the inner lining. The bootie may be arranged between the upper and inner lining. Methods of manufacturing the aforementioned footwear system are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S.Provisional Patent Application No. 61/911,696, filed Dec. 4, 2013, thedisclosure of which is hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

Aspects of the present invention relate, in general, to waterprooffootwear, and specifically to an adjustable waterproof bootie for use infootwear of different sizes and/or shapes.

Footwear developed to withstand water or other liquids must beconstructed to keep a user's feet dry upon contact with such water orother liquids. To that end, it is known to utilize a waterproof layer ofmaterial within certain shoe constructions to prevent water or anotherliquid from permeating through the shoe. For instance, some waterproofshoe constructions involve the use of a waterproof liner that ispositioned under an upper of the shoe. The liner prevents water frompermeating all the way through the shoe and to the user's foot.

In such constructions, however, shoes of different sizes generallyutilize an individually-sized liner that is dedicated exclusively to thespecific shoe size. While this type of construction may be effective, itnonetheless requires a number of specifically-sized components toproduce the waterproof liner, and the liner is not usable with shoes ofdifferent sizes and/or shapes. Unfortunately, this can increase the timeand expense needed to mass-manufacture the aforementioned waterproofshoes. Other deficiencies of such shoe constructions not noted here alsoexist.

BRIEF SUMMARY OF THE INVENTION

Aspects of the present invention provide a seamless waterproof bootiethat can be adjusted to fit shoes of different sizes and/or shapes.

A first embodiment of the present invention includes a shoe having anupper with exterior and interior surfaces, a sole having an exteriorsurface for contacting the ground and an interior surface, the solebeing secured to the upper, wherein the interior surface of the upperand the interior surface of the sole define a cavity for receiving awearer's foot, an inner lining being arranged within the cavity, and aseamless bootie formed of waterproof material in a sock shape, theseamless bootie overlying the inner lining within the cavity andincluding one or more ribbed portions adapted to expand to allow thebootie to conform to the size of the inner lining, the seamless bootiebeing configured to shield a wearer's foot from contact with water oranother liquid. In certain aspects of the first embodiment, the seamlessbootie is made from a waterproof material that is selected from thegroup consisting of latex, polyurethane, rubber, or other materials thatcan be extruded or molded into a seamless, thin material layer.

A second embodiment of the invention includes a method of constructingfootwear comprising the steps of: (1) providing an upper, an innerlining, and a foot-shaped mold having an outer surface, the foot-shapedmold including at least one ribbed portion on its outer surface; (2)applying a waterproof material to the outer surface of the foot-shapedmold, thereby creating a seamless functional layer with at least oneribbed portion corresponding to the at least one ribbed portion on theouter surface of the foot-shaped mold, the seamless functional layerbeing in the form a seamless, sock-shaped bootie; (3) placing theseamless functional layer over the inner lining, such that the at leastone rib expands to conform the seamless bootie to the size of the innerlining; (4) placing the upper over the seamless functional layer; and(5) affixing a sole to the upper. Additionally, in other aspects of thesecond embodiment, the foot-shaped mold includes multiple ribbedportions, at least some of the ribbed portions being arranged transverseto a longitudinal axis of the foot-shaped mold.

A third embodiment of the invention includes an article forwaterproofing footwear comprising a seamless, sock-shaped bootie formedof waterproof material having at least one rib extending transverselyfrom a surface of the bootie, the seamless bootie being configured forinsertion over an inner lining of a shoe, and being adapted to conformto the size of the inner lining via the at least one rib. In someinstances, at least one rib is placed vertically along an instep area ofthe bootie, and at least one rib is arranged transverse to the verticalrib.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an exploded view of a shoe, according to one embodiment ofthe present invention.

FIG. 1B is a perspective view of a waterproof bootie formed from thefoot-shaped mold of FIGS. 3A-B, while FIG. 1C is a bottom perspectiveview of the bootie.

FIG. 2 is a perspective, partial cutaway view of the shoe of FIG. 1A inassembled form.

FIG. 3A is a perspective view of a foot-shaped mold utilized to form aseamless waterproof bootie, which is incorporated, for example, withinthe shoe of FIG. 2.

FIG. 3B is a bottom perspective view of the foot-shaped mold of FIG. 3A.

DETAILED DESCRIPTION

In describing certain features of the present invention, specificterminology will be used for the sake of clarity. However, the inventionis not intended to be limited to any specific terms used herein, and itis to be understood that each specific term includes all technicalequivalents, which operate in a similar manner to accomplish a similarpurpose.

FIG. 1A depicts a shoe 10 having an upper 20, a seamless sock-shapedbootie 30, an inner lining 50, and a sole 60. FIG. 1B further depictsthe seamless bootie 30, while FIGS. 3A-B depict a foot-shaped mold 70used to create the seamless bootie 30.

As shown in FIG. 1A, shoe upper 20, which comprises an exterior layer 26and an interior layer 27, may be constructed of different fabrics thatare sewn together. Upper 20 may include identifiable holes 22 to allowfor shoelaces to be placed therein, as in traditional shoeconstructions. In addition, upper 20 and sole 60 define an inner cavity24, which is dimensioned to allow for insertion of the seamless bootie30 and the inner lining 50 therein. Thus, seamless bootie 30 and innerlining 50 may be disposed under upper 20.

Upper 20 further includes a top perimeter portion 21. In one embodiment,the seamless bootie 30 and the inner lining are stitched or otherwisesecured to the upper 20 at perimeter portion 21 (e.g., duringconstruction of shoe 10). As such, traditional hung lining techniquesmay be used during construction of shoe 10, thereby connecting upper 20,seamless bootie 30, and inner lining 50 via stitching along perimeterportion 21 of upper 20.

The seamless bootie 30 is, in one embodiment, made from a waterproofmaterial(s) that is selected from the group consisting of latex,polyurethane, rubber, Ethyl Vinyl Acetate, or other materials that canbe extruded into a seamless, thin material layer (or any combination ofthe foregoing). As shown, the seamless bootie 30 includes one or morefunctional ribs 31-on its surface that have hollow insides open to aninner cavity 35 of the bootie 30. In a particular construction ofseamless booties 30, as illustrated in FIGS. 1B-C, one or more verticalribs 31 may be formed along an instep area of the bootie 30, one or moreribs 32 may be placed transverse in relation to the vertical rib 31, oneor more ribs 34 may be placed horizontally along a toe region 37 of thebootie 20, the rib(s) 34 spanning the ends of the toe region 37 of thebootie 30, and one or more ribs 33 may extend along a perimeter of toeregion 37. In one example, the rib(s) 33 may connect or be adjacent to arib 34. Also, in certain embodiments, any of ribs 31, 32, 34 maycompletely or partially encircle bootie 30, such that a section of theapplicable ribs 31, 32, 34 extends along a bottom surface of bootie 30(e.g., each rib 31, 32, 34 may form a continuous rib along the bottomsurface of bootie 30 or be spaced apart by a particular distance at thebottom surface of bootie 30, thereby forming multiple, discontinuous ribsegments 31, 32, 34). Continuous ribs are shown in FIG. 1C, whilediscontinuous ribs are not shown in the figures, but are nonethelesscontemplated. In other cases, ribs 31, 32, 34 may not be formed on thebottom surface of bootie 30. While a particular configuration of ribs31-34 is described herein, alternate configurations are contemplated, ofcourse, and one or more ribs 31-34 may be removed from bootie 30, oralternatively other ribs (not shown) may be added to improve thefunctionality of bootie 30. As discussed herein, ribs 31-34 areconfigured to enable expansion of the bootie 30 to adjust to differentshoe sizes as well as different shoe shapes.

Returning to FIG. 1A, an inner lining 50 may comprise various pieces offabric that are sewn together to form a sock-shaped lining 50. As shown,in one embodiment the fabric pieces of inner lining 50 are stitchedtogether to form a sock shape, such that a user's foot may beaccommodated within lining 50. Alternatively, other inner linings asknown in the art may be utilized with shoe 10. In addition, while notdepicted in the figures, a foot bed may be provided with shoe 10 (e.g.,for placement between outsole 60 and inner lining 50 of shoe 10). Insome cases, the foot bed may be stitched, cemented, or otherwise adheredto the upper 20 of shoe 10.

FIGS. 3A-B depict a foot-shaped form or mold 70, which may be utilizedto manufacture seamless bootie 30. Foot-shaped mold 70 includes ribbedportions 71-74 that roughly, or in some cases exactly, mirror ribs 31-34of seamless bootie 30. As shown, foot-shaped mold 70 includes a toeregion 75 and a mid-foot region 76 and a longitudinal axis extendingfrom mid-foot region 76 to toe region 75. As with bootie 30, one or morevertical ribs 71 are created along mid-foot region 76 of the foot-shapedmold 70, one or more ribs 72 are placed transverse in relation to the atleast one vertical rib 71, one or more ribs 74 are arranged transverseto the longitudinal axis of foot-shaped mold 70 along toe region 75, andone or more ribs 75 are situated along a perimeter of toe region 75. Insome case, as shown in FIG. 3B, ribs 71, 72, 74 can extend along abottom surface of foot-shaped mold 70, such that a continuous rib isformed. Alternatively, although not shown, any of ribs 71, 72, 74 may bespaced apart along the bottom surface of mold 70 so that a discontinuousrib is formed. These ribbed portions 71-74 may be imparted onto thebootie 30 according to the method discussed below.

To construct seamless bootie 30 from foot-shaped form or mold 70, asdepicted in FIGS. 3A-B, one may first provide a body of material(s) thatis impermeable to water or other liquids, such as a body of latex,polyurethane, rubber, Ethyl Vinyl Acetate, or other water proofmaterials that can be extruded/molded into a seamless, thin materiallayer (or a combination of any of the aforementioned materials). Themold may then be dipped into the body of latex or other such material(s)using, for example, an automated process. After coating an outer surfaceof the foot-shaped mold 70 with the latex or other material(s), mold 70may be removed from the vat of material(s), the material(s) may beallowed to cure, and then the material(s) may be removed from mold 70 toform seamless bootie 30. Bootie 30 then includes ribs 31-34 thatsubstantially or exactly mirror ribs 71-74 formed on foot-shaped mold70. In an alternate embodiment, prior to removing the waterproofmaterial(s) from mold 70, mold 70 may be dipped into the body ofmaterial(s) one or more additional times to further coat foot-shapedmold's 70 outer surface with the latex or other material(s). Thematerial(s) may then be allowed to cure, at which point it can beremoved from mold 70 to form a multi-layered seamless bootie 30. In someinstances, during this process foot-shaped mold 70 may be immersed inthe same material(s) multiple times, or mold 70 may be dipped into afirst material(s) one or more times, and then into a second material(s)one or more times. Mold 70 may also be dipped into the vat of latex orother material(s) at an angle sufficient to keep air bubbles from beingtrapped between the mold 70 and the cured latex/material(s) so as tokeep the cured latex/material(s) free of air bubbles once solidified.

During the curing of the material(s), it is also contemplated that astimulus of some form may be used, such as heat provided by a heatsource (not shown), to assist with curing of the material(s) applied tofoot-shaped mold 70. Other stimuli besides heat, such as a combinationof heat and forced air, might also be used to assist with curing of thewaterproof material(s). Particular releasing agents and/or a coagulantmay also be used with mold 70 to more easily allow the material(s) to beremoved from mold 70 after it cures. A coagulant coating on the mold 70may, for instance, help the latex or other material(s) to form a skin onthe mold 70 allowing for easier release.

After construction of seamless bootie 30 according to the foregoingmethod, it may be incorporated into shoe 10, as follows. Inner lining 50(FIG. 1A) may first be inserted into inner cavity 35 of seamless bootie30, which is dimensioned to receive lining 50. Thus, seamless bootie mayoverlie substantially all or a portion of inner lining 50. Once situatedthereon, one or both of seamless bootie 30 and inner lining 50 may bestitched to upper 20 of shoe 10 at its top perimeter portion 21.Alternatively, the bootie 30 and/or lining 50 may be cemented orotherwise adhered to upper 20 (e.g., along perimeter portion 21 or atother sections of upper 20). For instance, once bootie 30 is placed overinner lining 50, it may be glued, cemented, or otherwise adhered toportions or all of interior layer 27 of upper 20. If bootie 30 andlining 50 are stitched to upper 20 at its top perimeter portion 21, theresulting punctures through bootie 30 due to the stitching may remainunsealed, or alternatively may be sealed using, for example, awaterproof tape or other such device. Lastly, an inner surface ofoutsole 60 may be engaged to the bottom of seamless bootie 30 (asarranged over inner lining 50) to complete shoe 10.

During construction of shoe 10, it is advantageous that ribs 31-34 ofseamless bootie 30 may act to accommodate, for example, variousdifferently-sized and/or shaped inner linings 50. For instance, aparticular seamless bootie 30, by virtue of any of ribs 31-34, may beusable with an inner lining that is designed to accommodate a user'sfoot of anywhere between U.S. men's or women's size 8-12. Alternatively(or in addition), such a bootie 30 may also be usable with footwearhaving differently-shaped inner linings 50, such as a general purposerunning shoe as compared to a hiking boot. Bootie 30 may adapt to theaforementioned situations via expansion of at least a portion of one ormore of its ribs 31-34 longitudinally, laterally, or in any alternatedirection. In other words, a particular rib, for example rib 34, maystretch or expand longitudinally by virtue of its position horizontallyacross toe region 37 of bootie 30, while another rib, for example rib32, may permit expansion of bootie 30 in its instep area in both avertical and longitudinal direction (the vertical direction extendingtop-to-bottom in FIGS. 1A-B, and the longitudinal direction extendingleft-to-right). Likewise, if the inner lining 50 includes, as anexample, an enlarged toe region (which might be the case in certainhiking boots), rib 33 extending along the perimeter of toe region 37 ofbootie 30 may act to expand and accommodate such an enlarged toe regionof inner lining 50. Ribs 34 may also, in some cases, expand to assist inaccommodating an enlarged toe region of the inner lining 50, if needed.

Bootie 30 including one or more of ribs 31-34, as described herein,therefore reduces the capital required to produce various waterproofshoes 10 (e.g., having different sizes and/or shapes). For instance, asribs 31-34 may expand to accommodate different shoe sizes and/or shapes,a manufacturer need not produce a specifically-sized mold 70 for use inthe method described herein, and may utilize a single or only a fewdifferently-sized molds 70 for the production of a seamless bootie 30that is usable with shoes of varying sizes/shapes. Thus, manufacturingcosts are decreased. In addition, time and labor are also decreased asit is not necessary to, for instance, change the particular foot-shapedmold 70 being used in an automated process for manufacturing seamlessbooties 30. Indeed, a single or only a few molds 70 may be utilized inthe creation of many seamless booties 30 without having to constantlysubstitute one specifically-sized mold 70 for another.

A completely-constructed shoe 10, shown in partial cutaway, is depictedin FIG. 2. As can be appreciated, seamless bootie 30 incorporatedbetween the shoe's upper 20 and its inner lining 50 (shown at thecutaway section) can provide waterproofing characteristics for a user inundertaking various activities. The user's foot is therefore adequatelyprotected from contact with water or other liquids during use. While ageneral purpose shoe is shown, seamless bootie 30 may be utilized in anydifferent type of shoe such as, for example, a hiking boot, a runningshoe, etc.

In the devices depicted in the figures, particular structures are shownthat are adapted for use in a waterproof shoe 10, and/or in methods ofconstructing the same. The use of alternative structures for suchpurposes, including structures having different lengths, shapes, andconfigurations is also contemplated. As an example, ribbed portions maybe placed along different locations of seamless bootie 30, other thanthose described above. For instance, one or more ribs may be placedvertically or horizontally along a heel portion of the bootie 30.Alternatively, or in addition, ribbed portions may also be placedlongitudinally along the bottom surface of the bootie 30. The ribbedportions, although rounded and semi-circular in shape, may also becreated in a wave, trapezoidal, triangular, or other shaped patterns solong as such ribs enable the bootie 30 to adjust to shoes of differentshapes and sizes. Also, any of the ribbed portions may be formed as adiscontinuous rib so that the particular rib(s) is broken into sectionsthat are individually spaced apart from one another and, in combination,form a substantially continuous rib(s). As an example, while rib 33 isshown as being continuous, it is equally contemplated that rib 33 couldbe formed into discrete sections so that a discontinuous rib 33 isformed that extends along a perimeter of toe region 37. The same is trueof the other ribs 31, 32, 34 and, by extension, any of ribs 71-74 ofmold 70.

While shoe 10 is also discussed as incorporating an inner lining 50, itis contemplated that inner lining 50 may be omitted and that solelybootie 30 may be situated along inner surface 27 of upper 20 to shield auser's foot from contact with water. In some cases, bootie 30 mayinclude one or more layers that act to substitute for inner lining 50,such as textile layers that are coated with a layer(s) of waterproofmaterial(s) (e.g., latex or the other materials mentioned above).

Although aspects of the invention herein have been described withreference to particular embodiments, it is to be understood that theseembodiments are merely illustrative of aspects of the present invention.It is therefore to be understood that numerous modifications may be madeto the illustrative embodiments and that other arrangements may bedevised without departing from the spirit and scope of the presentinvention as set forth in the appended claims.

It will also be appreciated that the various dependent claims and thefeatures set forth therein can be combined in different ways thanpresented in the initial claims. It will also be appreciated that thefeatures described in connection with individual embodiments may beshared with others of the described embodiments.

1. A shoe comprising: an upper having an exterior surface and aninterior surface; a sole having an exterior surface for contacting theground and an interior surface, the sole being secured to the upper,wherein the interior surface of the upper and the interior surface ofthe sole define a cavity for receiving a wearer's foot; an inner liningarranged within the cavity; and a seamless bootie formed of waterproofmaterial in a sock shape, the seamless bootie overlying the inner liningwithin the cavity and including one or more ribbed portions adapted toexpand to allow the bootie to conform to the size of the inner lining,the seamless bootie being configured to shield a wearer's foot fromcontact with water or another liquid.
 2. The shoe according to claim 1,wherein the seamless bootie entirely covers the inner lining.
 3. Theshoe according to claim 1, wherein the inner lining is composed ofpieces of fabric that are stitched together.
 4. The shoe according toclaim 1, wherein the waterproof material of the seamless bootie isselected from the group consisting of latex, polyurethane, rubber, EthylVinyl Acetate, or any combination of thereof.
 5. The shoe according toclaim 1, wherein the bootie includes multiple ribbed portions configuredto expand so that the bootie conforms to the size of the inner lining,at least some of the ribbed portions being arranged transverse to alongitudinal axis of the bootie.
 6. The shoe according to claim 1,wherein the bootie includes a toe region with a perimeter, and the oneor more ribbed portions extend along a portion of the perimeter of thetoe region.
 7. A method of manufacturing a shoe, the method comprising:providing an upper, an inner lining, and a foot-shaped mold having anouter surface, the foot-shaped mold including at least one ribbedportion on its outer surface; applying a waterproof material to theouter surface of the foot-shaped mold, thereby creating a seamlessfunctional layer with at least one ribbed portion corresponding to theat least one ribbed portion on the outer surface of the foot-shapedmold, the seamless functional layer being in the form a seamless,sock-shaped bootie; placing the seamless functional layer over the innerlining, such that the at least one rib expands to conform the seamlessbootie to the size of the inner lining; placing the upper over theseamless functional layer; and affixing a sole to the upper.
 8. Themethod according to claim 7, wherein the upper is stitched to a foot bedthat is interposed between the sole and the upper.
 9. The methodaccording to claim 7, wherein the foot-shaped mold includes multipleribbed portions on its outer surface, at least some of the ribbedportions being arranged transverse to a longitudinal axis of the mold.10. The method according to claim 9, wherein the foot-shaped moldincludes a toe region with a perimeter, and at least one of the ribbedportions extends along a portion of the perimeter of the toe region. 12.The method according to claim 7, further comprising the step ofimmersing the foot-shaped mold in a body of waterproof material to covera substantial amount of the mold's outer surface with the waterproofmaterial.
 13. The method according to claim 12, further comprising thesteps of removing the foot-shaped mold from the body of waterproofmaterial, and heating the foot-shaped mold and waterproof material tocure the waterproof material.
 14. The method according to claim 7,wherein foot-shaped mold includes one or more ribs at a heel portion ofthe mold.
 15. An article for waterproofing footwear comprising aseamless, sock-shaped bootie formed of waterproof material, the seamlessbootie having at least one rib extending transversely from a surface ofthe bootie and being configured for insertion over an inner lining of ashoe, wherein the bootie is adapted to conform to the size of the innerlining via the at least one rib.
 16. The article according to claim 15,wherein the seamless bootie includes multiple ribs.
 17. The articleaccording to claim 16, wherein the seamless bootie includes a toe regionwith a perimeter, and at least one of the ribs extends along a portionof the perimeter of the toe region.
 18. The article according to claim15, wherein at least one rib is placed vertically along an instep areaof the bootie.
 19. The article according to claim 18, wherein at leastone rib is placed transverse in relation to the vertical rib on thebootie.
 20. The article according to claim 15, wherein the waterproofmaterial of the seamless bootie is selected from the group consisting oflatex, polyurethane, rubber, Ethyl Vinyl Acetate, or any combination ofthereof.